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Tougher than steel: Wood pulp could make lighter auto parts

KYOTO, Japan — The global push among carmakers to make ever lighter vehicles is leading some auto suppliers in Japan to turn to what seems like an unlikely steel substitute — wood pulp. Japanese researchers and auto component makers say a material made from wood pulp weighs just one-fifth of steel and can be five times stronger. The material - cellulose nanofibers — could become a viable alternative to steel in the decades ahead, they say, although it faces competition from carbon-based materials, and remains a long way from being commercially viable.> Related: Jay Leno drives the Renew cannabis car — hemp you can't dent Reducing the weight of a vehicle will be critical as manufacturers move to bring electric cars into the mainstream. Batteries are an expensive but vital component, so a reduction in car weight will mean fewer batteries will be needed to power the vehicle, saving on costs. "Lightweighting is a constant issue for us," said Masanori Matsushiro, a project manager overseeing body design at Toyota. "But we also have to resolve the issue of high manufacturing costs before we see an increased use of new, lighter-weight materials in mass-volume cars."A NEW PROCESS Researchers at Kyoto University and major parts suppliers such as Denso Corp, Toyota's biggest supplier, and DaikyoNishikawa Corp, are working with plastics incorporated with cellulose nanofibers — made by breaking down wood pulp fibers into several hundredths of a micron (one thousandth of a millimeter). Cellulose nanofibers have been used in a variety of products ranging from ink to transparent displays, but their potential use in cars has been enabled by the "Kyoto Process," under which chemically treated wood fibers are kneaded into plastics while simultaneously being broken down into nanofibers, slashing the cost of production to roughly one-fifth that of other processes. "This is the lowest-cost, highest-performance application for cellulose nanofibers, and that's why we're focusing on its use in auto and aircraft parts," Kyoto University Professor Hiroaki Yano, who is leading the research, told Reuters in an interview. The university, along with auto parts suppliers, are currently developing a prototype car using cellulose nanofiber-based parts to be completed in 2020.

Bauer Catfish is a Miata-based trackstar in the making [w/videos]

We're not trying to make a joke here. The creation you see above really is called the Bauer Catfish, and while the name is about as attractive as your average bottom feeder, the car itself is built on a sexy notion. Take the mechanical bits of one 1990-2005 Mazda MX-5 Miata, add in a tube chassis for as little weight as possible, complete with some custom body work and go forth. Bauer says the finished product weighs in at just 1,550 pounds, and the company will be happy to pull the stock four-cylinder to drop in a healthy General Motors LS V8.
The pre-production prototype shown above competed in last year's 25 Hours of Thunderhill, finished the race and earned a spot on the podium in the "anything goes for sports racers" ESR class. Very cool.
If you're looking for a dedicated track car, it may not get any better than this for the money. Expect to pay around $13,900 depending on options, plus the cost of your donor Miata. That's a good sight cheaper than a used Chevy Corvette Z06 and likely to be quite a bit more fun. After you're done watching it in action in the brief videos below, check it out over at Bauer Ltd.

Will the Mazda2 be offered as a PHEV with a rotary engine range extender?

Every few months, it seems a rumor crops up about plans from Mazda to revive the rotary engine. Last November, its CEO said the only way another one could happen is if the project was profitable, and then a month later the automaker showed off the Mazda2 RE Range Extender with a 330cc Wankel engine mounted in the rear. Now, Australian auto site Motoring reports that the PHEV may actually make production in the next-gen Mazda2 sometime after it's initial launch.
Martin Benders, managing director of Mazda in Australia, spoke to Motoring about the company's future with hybrids and basically reiterated what the CEO said last year. The Japanese automaker only plans to offer electrified powertrains in places where they can sell in sufficient numbers to be profitable, like Japan.
Mazda has been playing with the rotary range-extender idea for years. In the RE prototype, the engine was exclusively used to charge the lithium-ion batteries when they were running low, and a 100-horsepower electric motor provided all of the propulsion. It gave the little hatch an estimated range of about 250 miles. The company reportedly took inspiration from its Skyactiv engines to make the Wankel have lower friction and a lighter weight.